Multiple pallet assembly

ABSTRACT

A pallet assembly includes a support base including a support deck having a plurality of openings. A plurality of pallets each include a pallet deck having a plurality of feet extending downward therefrom. The plurality of pallets are arranged such that the plurality of feet are received in the plurality of openings in the support deck of the support base. In this manner, a plurality of smaller pallets can be handled as a single standard size pallet, including being stacked in a pallet rack.

BACKGROUND

Standard size pallets, including plastic pallets, are used to supportgoods above a floor so that they can be lifted and moved by fork tines,such as on a fork lift. For storage or shipping, the pallets may beloaded into a rack where the loaded pallets are supported only at outeredges on rails in the pallet rack.

Sometimes it is more convenient to use half-size pallets, especiallywhen the pallets are intended to be delivered into a store or into arefrigerator or freezer where a standard-size pallet would be unwieldy.However, in a warehouse or distribution facility where there is plentyof room for standard size pallets, the half pallets still require twiceas much handling, because the fork lift will have to handle eachhalf-pallet separately. Further, the half-pallets cannot be stored on apallet rack.

SUMMARY

A pallet assembly includes a support base including a support deckhaving a plurality of openings therethrough. A plurality of pallets eachinclude a pallet deck having a plurality of feet extending downwardtherefrom. The plurality of pallets are arranged such that the pluralityof feet are received in the plurality of openings in the support deck ofthe support base.

In this manner, a plurality of smaller pallets can be handled at thesame time as if they were a single standard size pallet. Further, theplurality of pallets in the assembly with the support base can bestacked in a pallet rack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a multiple pallet assembly according toa first embodiment.

FIG. 2 is a perspective view of the support base of FIG. 1.

FIG. 3 is a front view of the pallet assembly of FIG. 1.

FIG. 4 is a side view of the pallet assembly of FIG. 1.

FIG. 5 is a front view of the pallet assembly of FIG. 1 with the supportbase raised to a lifting or racked position.

FIG. 6 is a side view of the pallet assembly of FIG. 5.

FIG. 7 is a perspective view of the pallet assembly and rack rails ofFIG. 5.

FIG. 8 is a front view of the support base of FIG. 1.

FIG. 9 is a side view of the support base of FIG. 1.

FIG. 10 is a perspective view of a multiple pallet assembly according toa second embodiment.

FIG. 11 is an exploded view of the pallet assembly of FIG. 10.

FIG. 12 is a top view of the pallet assembly of FIG. 10.

FIG. 13 is a bottom view of the pallet assembly of FIG. 10

FIG. 14 is a perspective view of the support base of FIG. 14.

FIG. 15 is a side view of the support base of FIG. 14.

FIG. 16 is a front view of the support base of FIG. 14.

FIG. 17 is a top view of the support base of FIG. 14.

FIG. 18 is a front view of the pallet.

FIG. 19 is a side view of the pallet.

FIG. 20 is a bottom view of the pallet.

FIG. 21 is a front view of the pallet assembly of FIG. 10 supported onrack rails.

FIG. 22 is a side view of the pallet assembly of FIG. 10.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

A pallet assembly 10 according to a first embodiment is shown in FIG. 1.The pallet assembly 10 includes a plurality of pallets 12 (in thisexample, two) and a support base 14. Each of the pallets 12 may beinjection molded as a single piece of plastic or as more than one piecesubsequently joined together as known. The support base 14 may also beinjection molded as a single piece of plastic or as more than one piecesubsequently joined together with known techniques.

The pallets 12 are nestable pallets 12 each having a deck 16 supportedabove the floor by a plurality of columns or feet 18. Openings 20through the deck 16 are aligned with the feet 18 so that the feet of anidentical pallet 12 can be nested therein. In this example, each pallet12 includes four corner feet 18 and a pair of side feet 18 (which couldbe considered a single, split foot 18) along each long edge of thepallet 12.

In FIG. 1, the pallets 12 are positioned on the support base 14, whichis on a floor. The feet 18 of the pallets 12 contact the floor.

FIG. 2 is a perspective view of the support base 14. The support base 14includes a deck 22 having a pair of fork tine-receiving recesses 24 onits underside. The deck 22 is supportable on the floor on base portions26. The tine-receiving recesses 24 are between the base portions 26. Aplurality of openings 28 are formed through the deck 22 in the patternof the feet 18 of the pallets 12 (FIG. 1). A plurality of reinforcementmembers 30 (such as steel rods, tubes, composite materials or stiffermaterials, etc) are secured to the deck 22 of the support base 14 andextend across the long dimension of the deck 22. The deck 22 may includean upper panel portion with a plurality of ribs extending downwardlytherefrom. The reinforcement members 30 may be secured between the ribson the underside of the deck 22.

FIG. 3 is a front view of the pallet assembly 10 of FIG. 1. The columns18 of the pallets 12 are received in the openings 28 in the support base14. The columns 18 contact the floor through the openings 28 and aresupported on the floor. In this position, the fork of a forklift can beinserted through the openings defined between the columns 18 and betweenthe deck 16 and the deck 22 to lift the pallet 12 away from the supportbase 14. Alternatively, the fork can be inserted through the fork tinereceiving recesses 24 of the support base 14, so that the forklift canlift both pallets 12 and the support base 14. FIG. 4 is a side view ofthe pallet assembly 10 of FIG. 3.

When the pallet assembly 10 is lifted by the fork tines below the deck22 of the support base 14, the support base 14 rises up the columns 18of the pallet 12 until the deck 22 of the support base 14 contacts thedecks 16 of the pallets 12, as shown in FIGS. 5 and 6. Then, the forklift can lift both pallets 12 with the support base 14.

As shown in FIG. 6, the side columns 18 of the pallets 12 are receivedon either side of the center one of the reinforcement members 30. Thisis why the side columns 18 are split into two side columns 18.

As is also shown in FIGS. 5 and 6, when supported on the support base14, the pallets 12 can be supported on a rack having end rails 32. Theend rails 32 support the support base 14 outward of the corner columns18 and are perpendicular (or at least substantially perpendicular) tothe reinforcement members 30. A perspective view of the pallet assembly10 supported on the rack (and end rails 32) is shown in FIG. 7.

FIG. 8 is a front view of the support base 14. FIG. 9 is a side view ofthe support base 14.

Another pallet assembly 110 according to a second embodiment is shown inFIG. 10. The pallet assembly 110 includes a plurality of pallets 112 (inthis example, two) and a support base 114. Each of the pallets 112 maybe injection molded as a single piece of plastic or as more than onepiece subsequently joined together as known. The support base 114 mayalso be injection molded as a single piece of plastic or as more thanone piece subsequently joined together as known.

The pallets 112 are nestable pallets 112 each having a deck 116supported above the floor by a plurality of columns or feet 118 (shownin FIG. 11). Openings 120 through the deck 116 are aligned with the feet118 so that the feet of an identical pallet 112 can be nested therein.In this example, each pallet 112 includes four corner feet 118 and apair of side feet 118 (which could be considered a single, split foot118) along each long edge of the pallet 112. Opposing sides of thepallets 112 include recesses 124 on the underside, and the otheropposing sides of the pallets 112 include recesses 121 on the underside.The recesses 124 have a greater height than the recesses 121.

In FIGS. 10, 11, 12 and 13, the pallets 112 are positioned on thesupport base 114, which is on a floor. FIG. 12 shows a top view of thepallet assembly 110, and FIG. 13 shows a bottom view of the palletassembly 110.

FIGS. 14, 15, 16 and 17 show the support base 114 that is supportable onthe floor. FIG. 14 shows a perspective view of the support base 114,FIG. 15 shows a side view of the support base 114, FIG. 16 shows a frontview of the support base 114, and FIG. 17 shows a top view of thesupport base 114. The support base 114 includes an upper deck portion122 and a lower deck portion 123.

A plurality of columns 128 are formed through the deck 122 in thepattern of the feet 118 of the pallets 112 (FIG. 10). The columns 128are each defined by wall section 133 that each extend between the upperdeck portion 122 and the lower deck portion 123. The columns 128 eachdefine an opening in the upper surface of the support base 114 down tothe lower deck portion 123. In one example, a space 125 is definedbetween the upper deck portion 122 and the lower deck portion 123. Thefeet 118 of the pallets 112 contact floor ribs 135 of the support base114 (shown in FIG. 17) of each of the columns 128 near the floor.

The upper deck portion 122 includes three pairs of upper deck segments122 a that are each substantially parallel to each other. Each pair ofthe upper deck segments 122 a is separated by one of the columns 128.The upper deck portion 122 also includes three pairs of upper decksegments 122 b that are substantially parallel to each other andsubstantially perpendicular to the pairs of the upper deck segments 122a. Each pair of the upper deck segments 122 b is also separated by oneof the columns 128. In one example, the upper deck segments 122 a arespaced higher from the floor than the upper deck segments 122 b arespaced from the floor. In one example, there are four openings 127defined in the upper deck portion 122 and the lower deck portion 123between the pairs of upper deck segments 122 a and 122 b.

In one example, the columns 128 that receive the column 118 of adjacentpallets 112 can be combined into a single opening that receives a column118 of adjacent pallets 112 or be a single opening that includes abarrier wall that separates the single opening into two sections thateach receive a column 118 of adjacent pallets 112.

FIGS. 18, 19 and 20 show a pallet 112, as explained above. FIG. 18 showsa front view of the pallet 112, FIG. 19 shows a side view of the pallet112, and FIG. 20 shows a bottom view of the pallet 112. A plurality ofribs 139 and 141 extend downwardly from the deck 116 of the pallets 112.The plurality of ribs 139 are located near the side of the pallets 112with the recesses 124 (located at least partially above the upper decksegments 122 b), and the plurality of ribs 141 are located near the sideof the pallets 112 with the recesses 121 (located at least partiallyabove the upper deck segments 122 a). The plurality of ribs 141 extendcloser to the floor than the plurality of ribs 139.

FIG. 21 shows a front view of the pallet assembly 110 of FIG. 1, andFIG. 22 shows a side view of the pallet assembly 110 of FIG. 1. Thecolumns 118 of the pallets 112 are received in the columns 128 of thesupport base 114. The plurality of ribs 141 contact the upper decksegments 122 a of the support base 114. The plurality of ribs 139 do notcontact the upper deck segments 122 b of the support base 114. A space119 is defined between the plurality of ribs 139 near the upper decksegments 122 b and the support base 114 so that the forklift can bereceived within the space 119 and under the pallets 112 to lift thepallets 112 relative to the support base 114. Alternatively, theforklift can be received within the space 125 to lift both the pallets112 and the support base 114 together.

FIG. 21 shows the pallet assembly 110 supported on end rails 132 in arack. When supported on the support base 114, the pallets 112 can besupported on a rack having end rails 132. The end rails 132 support thesupport base 114 outward of the corner columns 118

Optionally, a plurality of reinforcement members (such as steel rods,tubes, composite materials or stiffer materials, etc) may be used toreinforce the upper deck portion and/or the lower deck portion.

In accordance with the provisions of the patent statutes andjurisprudence, exemplary configurations described above are consideredto represent a preferred embodiment of the invention. However, it shouldbe noted that the invention can be practiced otherwise than asspecifically illustrated and described without departing from its spiritor scope.

What is claimed is:
 1. A pallet assembly comprising: a support baseincluding a support deck having a plurality of openings therethrough;and a plurality of pallets, each including a pallet deck having aplurality of feet extending downward therefrom, the plurality of feetreceived in the plurality of openings in the support deck.
 2. The palletassembly of claim 1 wherein the plurality of feet extend down throughthe support deck, such that the plurality of feet can be supported on afloor.
 3. The pallet assembly of claim 2 wherein the pallet decks eachinclude a plurality of openings for receiving the feet of identicalpallets nested thereon.
 4. The pallet assembly of claim 3 wherein thesupport base includes a plurality of fork tine-receiving recessesdefined below the support deck.
 5. The pallet assembly of claim 4wherein the pallet support base is supported at opposite ends in apallet rack.
 6. The pallet assembly of claim 1 wherein the support baseincludes an upper deck portion spaced above a lower deck portion.
 7. Thepallet assembly of claim 6 wherein the support base includes a pluralityof columns defining the plurality of openings therethrough.
 8. Thepallet assembly of claim 7 wherein the pallet support base is supportedat opposite ends in a pallet rack.
 9. A pallet support base comprising:a support deck having a plurality of openings therethrough, the supportdeck including an upper support surface, a plurality of forktine-receiving recesses defined below the support deck.
 10. The palletsupport base of claim 9 further including a plurality of ribs extendingdownward from the upper support surface, the fork tine-receivingrecesses defined by the plurality of ribs.
 11. A pallet support basecomprising: a support deck having a plurality of openings therethrough,the support deck including an upper support surface, wherein the supportbase includes an upper deck portion spaced above a lower deck portion.12. The pallet assembly of claim 11 wherein the support base includes aplurality of columns defining the plurality of openings therethrough.13. The pallet assembly of claim 12 wherein the pallet support base issupported at opposite ends in a pallet rack.
 14. The pallet assembly ofclaim 12 wherein the upper deck portion extend between the plurality ofcolumns.